Champion Power Equipment 30002 User manual

Brand
Champion Power Equipment
Model
30002
Category
Air compressors
Type
User manual
30002
Rev 30002-20080208
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670 USA
Made in China
5.5 Gallon
AIR COMPRESSOR
Owner’s Manual and Operating Instructions
Table of Contents
Introduction ..................................... 1
This Booklet .............................................. 1
Manual Conventions ......................... 2
Safety Rules ...................................... 3
Controls and Features ....................... 5
5.5 gallon Air Compressor ........................ 5
Assembly .......................................... 6
Add Compressor Oil ................................. 6
Attach Air Filter ........................................ 6
Break-In Procedure .................................. 6
Operation ......................................... 7
Start Up Procedure ................................... 7
Shutdown and Storage ............................. 7
Maintenance ..................................... 8
Compressor Maintenance ........................ 8
Oil Change ............................................. 8
Checking Safety Relief Valve ................ 8
Air Filter ................................................ 8
Maintenance Schedule .......................... 8
Specifications ................................... 9
5.5 gallon Tank Portable Air Compressor 9
Parts Diagram ......................................... 10
Parts List .................................................. 11
Troubleshooting ............................. 13
Warranty ........................................ 15
Warranty Qualifications ......................... 15
Repair/Replacement Warranty .............. 15
Do not return the unit to the place of
purchase .................................................. 15
Warranty Exclusions ............................... 15
Normal Wear ....................................... 15
Installation, Use and Maintenance ..... 15
Other Exclusions ................................. 15
Limits of Implied Warranty and
Consequential Damage ........................... 15
Contact Information ............................... 15
Address ................................................ 15
Customer Service ................................ 15
Technical Service ................................. 15
Notes .............................................. 16
Introduction
Rev 30002-20080208 1
Introduction
Congratulations on your purchase of a
Champion Power Equipment Air
Compressor. With proper use and
maintenance, this air compressor will bring
years of satisfying service.
This Booklet
Every effort has been made to ensure the
accuracy and completeness of the
information in this manual. We reserve the
right to change, alter and/or improve the
product and this document at any time
without prior notice.
Record the model and serial numbers as well as date and place of purchase for future reference.
Have this information available when ordering parts and when making technical or warranty
inquiries.
Champion Power Equipment Support
1-877-338-0999
Model Number
30002
Serial Number
Date of Purchase
Purchase Location
Manual Conventions
2 Rev 30002-20080208
Manual Conventions
This manual uses the following symbols to
help differentiate between different kinds of
information. The safety symbol is used with
a key word to alert you to potential hazards
in operating and owning power equipment.
Follow all safety messages to avoid or reduce
the risk of serious injury or death.
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided,
will
result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided,
could
result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided,
may
result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided,
may
result in property damage.
NOTE
If you have questions regarding your air
compressor, we can help. Please call our help line
at 1-877-338-0999.
Safety Rules
Rev 30002-20080208 3
Safety Rules
WARNING
Read this manual thoroughly before operating
your air compressor. Failure to follow instructions
could result in serious injury or death.
WARNING
Particulate Matter from user applications
Dust created by spraying, blowing, power
sanding, sawing, grinding, drilling and other
construction activities contains chemicals
known to the state of California to cause
cancer, birth defects or other reproductive
harm. Reduce exposure to these chemicals
by wearing approved safety equipment.
DANGER
Risk of Tank Bursting
Do not adjust regulator to result in output
pressure greater than marked maximum
pressure of attachment. If a regulator has
not been installed, use only attachment
rated at 120 PSI or higher. Do not weld on
or repair tank – A damaged tank must be
replaced. Do not operate without proper
valve connection.
Never attempt to repair or make
modifications to the tank or its attachments.
Welding, drilling, or any other modifications
may weaken the tank, which may result in
damage from rupture or explosion.
Never remove or attempt to adjust the
pressure switch, safety valve or other
components that control tank pressure.
DANGER
Risk of Electrical Shock
Disconnect air compressor from power
source before servicing. USE PROPERLY
grounded ELECTRICAL CONNECTIONS —
DO NOT use grounding adaptors. Do not
use in wet or damp locations or expose to
rain. Keep all connections dry and off the
ground. Do not allow power cords to come
into contact with water. Do not touch the
plug with wet hands. Do not pull on the
electrical cord to disconnect from
the power outlet. Store air compressor
indoors when not in use.
WARNING
Do not inhale compressed air
This air compressor is not designed, nor
intended for the supply of breathable quality
air. Air produced by this unit may contain
carbon
monoxide or other toxic vapors. Do not
inhale air from the compressor or from a
breathing device connected to it.
WARNING
Air Compressor generates significant heat
Touching exposed metal such as the
compressor head or exhaust tube can result
in serious burns. Keep hands and fingers
away from exposed metal parts on air
compressor during or immediately after
operation. Air compressors generate
significant heat during normal
operation and will remain hot for some time
after use.
Safety Rules
4 Rev 30002-20080208
WARNING
Compressed air stream can be harmful to people
or pets
The powerful compressed air stream can
damage exposed skin and easily propel
loose dirt, and other small objects at high-
speed, resulting in injury.
Always wear eye protection that meets ANSI
Z28.1 specifications.
Shut OFF air compressor and relieve
pressure before performing maintenance or
repairs. Do not move the air compressor
while the air tank is pressurized. Never
attempt to move the air compressor by
pulling on the air hose.
WARNING
Movement from Vibration
Always operate air compressor in a stable
and secure position to prevent accidental
movement of the unit. Never operate air
compressor on a roof or other elevated
position. Use additional air hose to reach
high locations.
WARNING
Air Tools and Accessories
Do not exceed the pressure rating of any air
tools, spray guns, air accessories, or
inflatables.
Excess pressure can cause them to explode,
resulting in serious injury. Follow the
manufacturers recommended pressure
settings for all air tools and air accessories.
WARNING
Release air and liquid from tank before and after
each use
Use the drain valve located on the bottom of
the lower air tank to drain. Failure to
properly drain liquid from the tank will cause
rust from moisture buildup, which weakens
the tank and could lead to a violent tank
explosion. Periodically inspect the tanks for
unsafe conditions such as corrosion, cracked
welds, and leaks.
When operating drain valve, release air and
liquid slowly when depressurizing the tank.
High speed release of air and liquid may stir
up rust and debris and may result in injury.
Controls and Features
Rev 30002-20080208 5
Controls and Features
Read this owner’s manual before operating your air compressor. Familiarize yourself with the
location and function of the controls and features. Save this manual for future reference.
5.5 gallon Air Compressor
(1) Rubber feet – to absorb vibration
when the compressor is running
(2) Outlet pressure gauge –Displays
pressure that is regulated through outlet
port
(3) Tank pressure gauge – Displays tank
pressure
(4) Motor Switch/Tank Regulator
housing –Control center for tank pressure.
(Motor switch on reverse side)
(5) Outlet pressure Regulator knob –
Turn knob to adjust outlet pressure
(6) Outlet coupler – Attach air
hose/accessories here
(7) Air filter housing –contains air filter
element. Protects pump from dust and
debris
(8) Oil Cap –(breather cap style) remove to
add oil
(9) Oil Level Sight glass– (not shown)
verify oil level here
Operation
6 Rev 30002-20080208
Assembly
Your air compressor requires some
assembly. This unit ships from our factory
without oil. It must be properly serviced
with oil before operation.
If you have any questions regarding the
assembly of your air compressor, call our
help line at 1-877-338-0999. Please have
your serial number and model number
available.
Add Compressor Oil
CAUTION
DO NOT attempt to start the compressor before
it has been properly filled with the recommended
type and amount of oil. Damage to the
compressor as a result of failure to follow these
instructions will void your warranty.
Use only SAE 30 Weight non-detergent air
compressor oil
1. Place the compressor on a flat, level
surface.
2. Remove oil cap to add oil.
3. Use provided oil bottle and pour oil into
crankcase until oil level reaches the
center of the red circle in oil level sight
glass. Do not overfill.
NOTE
Check oil often during the break-in period. Refer
to the Maintenance section for recommended
service intervals.
Attach Air Filter
1. Locate air filter among packed items
2. Twist on air filter to upper side of motor
housing. See figure (item 4) on previous
page.
Break-In Procedure
1. Please read and understand the entire
owner’s manual, including all safety
warnings before operating air
compressor.
2. Place air compressor on a flat, level
surface.
3. Check oil level in crankcase via the Oil
Sight glass and add oil as needed.
4. Open the tank drain valve to allow air
to escape preventing air pressure
buildup in the air tank.
5. Check that motor power switch is in
OFF position, then plug in power cord
into grounded outlet.
6. Turn compressor ON by moving switch
lever to AUTO/ON position and run the
compressor for 15 minutes. With the
drain valve open, this will cause the
motor to run continuously.
7. After about 15 minutes, with the motor
still running, close the tank drain valve.
This will allow the tank to build pressure
and automatically shut off once the tank
hits the maximum pressure. Notice tank
pressure gauge (125psi)
8. Slowly re-open the tank drain valve to
release air from tank. As the tank
pressure drops, the motor/pump will
automatically restart as it hits the
minimum preset pressure.
9. Turn compressor off by moving switch
lever to off position
10. Release residual pressure from tanks by
slowly opening air tank drain valve
11. Tilt tank to remove any moisture that
may remain in tank. Once completed,
close the valve securely.
12. Unplug compressor from power outlet
13. Your new Champion Air Compressor is
now ready to use
.
Operation
Rev 30002-20080208 7
Operation
Start Up Procedure
1. Before plugging compressor into power
outlet, make sure motor switch is in the
OFF position.
2. Place air compressor on a flat, level
surface.
3. Check oil level in crankcase via the Oil
Sight glass and add oil as needed.
4. Drain moisture from the air tank by
slowly opening the air tank drain valve
by turning clockwise. Once all the
moisture has drained out, close the
fitting securely
5. Turn output port regulator knob to a
closed position (counterclockwise)
6. Attach air hose and accessories.
7. Before plugging compressor into power
outlet check to see all components,
hoses, accessories, are all in working
order.
8. Plug power cord directly into a properly
grounded power source of the correct
voltage
9. Turn the compressor ON by moving the
motor switch to the AUTO/ON position.
Allow the tank pressure to build. Once
the air pressure reaches the preset
pressure maximum it will automatically
shut off.
10. Adjust regulator knob on outlet port to
appropriate pressure for particular
accessory
Shutdown and Storage
1. Turn the switch to the OFF position
2. Unplug compressor from power source
3. Turn the outlet pressure regulator knob
fully counterclockwise to close airflow to
port. Check pressure gauge that it reads
0 PSI
4. Remove air hose and any accessories
5. Slowly open tank drain valve to release
moisture from tanks. Tilt tank to
remove all moisture. When all moisture
has been removed, close the fitting
securely.
6. Allow the compressor motor to cool
down
7. Wipe down and store in a clean, dry, and
non-freezing location
Maintenance
8 Rev 30002-20080208
Maintenance
The owner/operator is responsible for all
periodic maintenance.
WARNING
Improper maintenance will void your warranty.
Complete all scheduled maintenance in a
timely manner. Correct any issue before
operating the air compressor.
NOTE
For service or parts assistance, contact our toll-
free help line at 1-877-338-0999.
Compressor Maintenance
Oil Change
Change oil when the engine is cool.
1. Remove the oil drain plug with a 15 mm
socket and extension.
2. Allow the oil to drain completely.
3. Replace the drain plug.
4. Remove oil fill cap to add oil.
5. Add Only SAE Weight 30 non-
detergent air compressor oil. Refer
to oil level sight glass for proper fill
level.
6. Dispose of used oil at an approved waste
management facility.
Checking Safety Relief Valve
1. Turn air compressor off and disconnect
from power source
2. Release tank pressure by opening tank
drain
3. Allow compressor to fully cool
4. Grasp wire ring on safety relief valve and
pull and release the ring a few times to
verify plunger movement
5. Replace safety relief valve if plunger is
not functional
Air Filter
1. Turn off air compressor and disconnect
from power source
2. Release tank pressure by opening tank
drain
3. Allow compressor to fully cool
4. Unscrew wing on filter body cover to
access the filter element.
5. Remove filter element. Use compressed
air to blow loose dirt and debris.
Replace filter element if it cannot be
cleaned sufficiently.
6. Reinstall filter element and reattach
cover to filter body
Maintenance Schedule
Follow the service intervals indicated in the
schedule below.
Service your air compressor more frequently
when operating in adverse conditions.
Every 8 hours or daily
Check oil level
First 20 Hours
Change oil
Every 200 hours or every 6 months
Change oil
Change oil more frequently if using in
dusty environments
6.
Specifications
Rev 30002-20080208 9
Specifications
5.5 gallon Tank Portable Air Compressor
Volt 115V/60Hz
Pump Oil Lubricated Direct Drive
Air Displacement 4.9CFM @ 40psi
3.9CFM @ 90psi
Max Pressure 115 PSI
Power 2.5HP max
2HP running
Motor Speed 3300 RPM
Tank Size 5.5 gallon
Rated Electricity 14 Amps
Specifications
10 Rev 30002-20080208
Parts Diagram
Specifications
Rev 30002-20080208 11
Parts List
No Part Number
Description
Qty
1 30002-01
BOLT M6*55
4
2 30002-02
SPRING WASHER M6
4
3 30002-03
CYLINDER HEAD
1
4 30002-04
EXHAUST ELBOW
1
5 30002-05
GASKET OF CYLINDER HEAD
1
6 30002-06
VALVE PLATE
1
7 30002-07
VALVE
2
8 30002-08
GASKET OF VALVE PLATE
1
9 30002-09
PISTON
1
10 30002-10
LOWER GASKET OF CYLINDER
1
11 30002-11
CYLINDER
1
12 30002-12
BOLT M8*25
2
13 30002-13
SPRING WASHER M8
2
14 30002-14
LOWER GASKET OF CYLINDER
1
15 30002-15
COMPRESSION RING
2
16 30002-16
OIL RING
1
17 30002-17
PISTON PIN
1
18 30002-18
CIRCLIP
2
19 30002-19
CONROD
1
20 30002-20
ECCENTRIC
1
21 30002-21
BOLT M8*22-LH
1
22 30002-22
OIL FILL CAP
1
23 30002-23
BOLT M6*18
8
24 30002-24
OIL SIGHT GAUGE
1
25 30002-25
SEAL OF OIL SIGHT GAUGE
1
26 30002-26
CRANKCASE COVER
1
27 30002-27
SEAL OF CRANKCASE COVER
1
28 30002-28
CRANKCASE
1
29 30002-29
OIL SEAL B20*40*7
1
30 30002-30
CAPACITOR
1
31 30002-31
NUT M8
3
32 30002-32
WASHER 8
1
33 30002-33
BOLT M3*6
2
34 30002-34
SPRING WASHER M3
2
35 30002-35
BEARING 6204-2RS
1
36 30002-36
ROTOR
1
37 30002-37
STATOR
1
38 30002-38
BEARING 6202-2RS
1
39 30002-39
WASHER 202
1
40 30002-40
BACK BEARING SEAT
1
41 30002-41
BOLT M5*105
4
42 30002-42
SPRING WASHER M5
4
43 30002-43
FAN
1
44 30002-44
CIRCLIP 14
1
45 30002-45
SHROUD
1
46 30002-46
TAPPING SCREW ST4.2*10
2
47 30002-47
WASHER M5
2
48 30002-48
OVERLOAD PROTECTOR
1
49 30002-49
SIGNATURE OF GROUNDING
1
50 30002-50
WASHER 4
1
51 30002-51
SCREW M4*6
1
52 30002-52
QUICK COUPLER
1
53 30002-53
Y40 PRESSURE GAUGE
2
54 30002-54
CONNECT OF PRESSURE GAUGE
1
55 30002-55
REGULATOR
1
Specifications
12 Rev 30002-20080208
No Part Number
Description
Qty
56 30002-56
CONNECT 1/4*27
1
57 30002-57
PRESSURE SWITCH
1
58 30002-58
CONNECT OF PRESSURE SWITCH
1
59 30002-59
STRAIN RELIEF
2
60 30002-60
SAFETY VALVE
1
61 30002-61
RELIEF NUT
1
62 30002-62
RELIEF TUBE
1
63 30002-63
POWER CORD
1
64 30002-64
CABLE CONNECTOR U
2
65 30002-65
CABLE CONNECTOR O
1
66 30002-66
TANK
1
67 30002-67
HANDLE GRIP
1
68 30002-68
CHECK VALVE
1
69 30002-69
DRAIN VALVE
1
70 30002-70
BASE PLATE OF PUMP
1
71 30002-71
RUBBER FOOT
4
72 30002-72
EXHAUST TUBE
1
73 30002-73
COMPRESSION NUT
2
74 30002-74
COPPER WASHER
2
75 30002-75
WASHER M5
4
76 30002-76
TAPPING SCREW ST4.8*16
4
77 30002-77
BOLT M8*55
4
78 30002-78
WASHER 8
8
79 30002-79
SPRING WASHER 8
1
80 30002-80
AIR FILTER KIT
1
Troubleshooting
Rev 30002-20080208 13
Troubleshooting
Problem Cause Solution
Air Compressor will not start Power cord Plug into grounded outlet
Motor Switch is in OFF position Move lever to auto/on position
Blown fuse, circuit breaker trip Replace fuse, reset circuit breaker
Unplug other appliances from same
outlet
Wrong gauge extension cord Check gauge on cord and verify that it
is the correct size
Tank pressure is greater than auto
motor “kick in”
Open tank drain valve to release tank
pressure
Defective motor, motor switch Call Champion Hotline #
Overheating Insufficient Ventilation Place compressor in environment with
well circulated supply of cool, dry air.
Dirty or obstructed cooling fins Clean surfaces of cooling fins on and
around pump/motor area
When in Auto/On position, motor
runs continuously
Motor switch malfunction- does not
respond when tank reaches max
pressure, safety relief valve engage
Move motor switch to OFF position.
If motor does not shut-off, unplug the
compressor. Evaluate motor switch
wiring. Replace if needed
Incorrect compressor size for tool
application
The Air tool might be too big for the
compressor you are using. Use a
smaller air tool, or a larger
compressor
Air leak after motor stops at switch
release valve
The check valve is stuck open Remove, clean or replace check valve
Air leak while motor is running at
switch release valve
Defective motor switch Replace
The check valve is stuck open Replace- NOTE – do not remove
while tank is pressurized. Release
tank pressure by opening tank drain
valve
Air leak from safety relief valve Malfunctioning safety relief valve Pull manually on ring. If valve does
not make a clean seal when closed,
replace.
Excessive Tank Pressure Defective motor switch. Replace
Air leaks at pump Malfunctioning/blown gaskets Replace poor gaskets
Air leaks in tank Rusted, broken welds – Defective tank Replace – Note – Do not attempt to
repair air tank!
Air leaks at fittings Fittings are not sufficiently tight Tighten fittings – Note- Do not over
tighten
Air blowing from intake filter Damage intake valve Contact Champion Hotline #
Insufficient pressure for air tool or
accessory
Air leaks Check for leaks on all fittings and
connections. Tighten or repair
connections as needed
Air compressor is not large enough for
particular air equipment
Note the equipment requirement – if
higher then pressure supply of
compressor, or causes the motor to
run continuously, you need a larger
air compressor
Pressure regulator is not set to
accurate pressure
Adjust pressure regulator knob to
correct setting
Restricted air intake Clean or replace filter element
Defective motor/pressure switch Replace
Hose or hose connection(s) are
inaccurate size
Assess and replace if necessary
Air compressor not making enough air Low compression Possible worn piston rings and/or
cylinder walls. Inspect and replace as
needed
Malfunctioning intake filter Clean or replace filter element
Leaking inlet valve Release all tank pressure, then
measure pump up time. Compare to
Troubleshooting
14 Rev 30002-20080208
Problem Cause Solution
specifications. If needed inspect and
replace valve components
Malfunctioning pilot valve Clean or replace
Moisture in discharge air Excessive condensation in air tank due
to atmospheric humidity
Always drain tank after use. Drain
more often in areas of high humidity.
Use air line filter
Warranty
Rev 30002-20080208 15
Warranty
CHAMPION POWER EQUIPMENT
1 YEAR LIMITED WARRANTY
Warranty Qualifications
Champion Power Equipment (CPE) will register
this warranty upon receipt of your Warranty
Registration Card and a copy of your sales receipt
from one of CPE's retail locations as proof of
purchase.
Please submit your warranty registration and
your proof of purchase within ten (10) days of the
date of purchase.
Repair/Replacement Warranty
CPE warrants to the original purchaser that the
mechanical and electrical components will be free
of defects in material and workmanship for a
period of one (1) year from the original date of
purchase (90 days for commercial & industrial
use). Transportation charges on product
submitted for repair or replacement under this
warranty are the sole responsibility of the
purchaser. This warranty only applies to the
original purchaser and is not transferable.
Do not return the unit to the place of
purchase
Contact CPE's Technical Service and CPE will
troubleshoot any issue via phone or e-mail. If the
problem is not corrected by this method, CPE
will, at its option, authorize evaluation, repair or
replacement of the defective part or component
at a CPE Service Center. CPE will provide you
with a case number for warranty service. Please
keep it for future reference. Repairs or
replacements without prior authorization, or at
an unauthorized repair facility, will not be
covered by this warranty.
Warranty Exclusions
This warranty does not cover the following
repairs and equipment:
Normal Wear
Compressors need periodic parts and service to
perform well. This warranty does not cover repair
when normal use has exhausted the life of a part
or the equipment as a whole.
Installation, Use and Maintenance
This warranty will not apply to parts and/or labor
if this compressor is deemed to have been
misused, neglected, involved in an accident,
abused, pressurized beyond the recommended
pressure or temperature limits, modified,
installed improperly or connected incorrectly to
any electrical component. Failure to follow
recommended operating and maintenance
procedure will also void this warranty.
Other Exclusions
This warranty excludes:
Cosmetic defects such as paint, decals, etc.
Pump or valve failure due to rain, excessive
humidity, corrosive environments or other
contaminants; rusted tanks including but not
limited to rust due to improper drainage or
corrosive environments.
Failures to due acts of God and other force
majeure events beyond the manufacturer’s
control.
Problems caused by parts that are not original
Champion Power Equipment parts.
This warranty does not apply to compressors
used for commercial or rental purposes.
Limits of Implied Warranty and
Consequential Damage
Champion Power Equipment disclaims any
obligation to cover any loss of time, use of this
product, freight, or any incidental or
consequential claim by anyone from using this
compressor. THIS WARRANTY IS IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE
A unit provided as an exchange will be subject to
the warranty of the original unit. The length of
the warranty governing the exchanged unit will
remain calculated by reference to the purchase
date of the original unit.
This warranty gives you certain legal rights which
may change from state to state. Your state may
also have other rights you may be entitled to that
are not listed within this warranty.
Contact Information
Address
Champion Power Equipment, Inc.
Customer Service
10006 Santa Fe Springs Rd.
Santa Fe Springs, CA 90670
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
Fax no.: 1-562-236-9429
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
tech@championpowerequipment.com
Notes
16 Rev 30002-20080208
Notes
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Champion Power Equipment 30002 User manual

Brand
Champion Power Equipment
Model
30002
Category
Air compressors
Type
User manual
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